Continuous roll towel apparatus and material

ABSTRACT

Apparatus for dispensing cloth, paper, and microfiber continuous roll toweling material interchangeably is shown along with apparatus for dispensing continuous flat weave split microfiber roll toweling. Microfiber continuous roll toweling material suitable for use in dispensing apparatus is described.

This invention relates to roll towel apparatus and more particularly to continuous roll towel dispensing devices in which the toweling is formed from extended lengths of microfiber material. This application claims benefit of Provisional Application No. 60/738,957 incorporated herein by reference in its entirety.

BACKGROUND OF INVENTION

Continuous roll towel dispensers in which a loop of towel material is fed out of a slot adjacent the front bottom edge of the dispenser and returned into the dispenser through a rear slot have been known for many years. See for instance U. S. Pat. No. 6,578,936 B1 which is incorporated herein by reference in its entirety Typically the towel material has been formed from cotton or linen and made into rolls having a length of twenty-five to fifty yards or so and a width of six to fifteen inches or so. Toweling of this sort has been expensive enough that most rolls of used toweling are removed from the dispenser, laundered and then reused. Typical life cycles for the rolls range from twenty to fifty or sixty reuses before the material is no longer useful.

In an attempt to overcome the laundering cost various dispensers have been introduced which dispense individual sheets from continuos rolls of paper. The individual sheets of paper towel are then discarded after use creating a refuse problem. Continuous paper roll toweling has presented serious obstacles to dispensing from a conventional dispensing apparatus such as shown in the above referenced patents. Recently there has been disclosed in U.S. Pat. No. 6,736,466 B1 a device for dispensing a loop of paper toweling from a continuous roll thereof for use and then rerolling up the used toweling which then may be disposed of in a more convenient and less volume consuming manner. The economic effect of paper in its various forms versus cloth has been and continues to be debated in the industry.

In addition to the problems, discussed in the '466 patent above, in handling and adapting synthetic toweling materials to continuous roll towel dispensers the industry has been plagued with the strength of the fiber necessary for the manual pulling operation of the traditional device without increasing the thickness of the fiber and thus making the rolls so large that very few uses could be supplied by the standard dispenser. The drying capability of the towel material and the number of washing cycles the material could withstand have also been significant problems.

We have now discovered that with the proper choice of a microfiber toweling material and the use of the improved roll towel dispensing apparatus disclosed herein we can overcome the above problems and provide an economically practical roll towel material and dispenser which allows a number of uses per roll comparable to conventional cloth and dispenses a superior roll towel material compared to traditional cloth and paper dispensers

For purposes of this disclosure “microfiber” material is defined to include material made from synthetic filament yarns of less than two denier and frequently fibers of less than one denier or 10 microns. These yarns are typically 100% polyester but can be made from a wide variety of synthetic polymers.

“Split microfiber” generally is made from a compound filament consisting of two different synthetic polymers (most often polyesters and polyamides) extruded together. The extruded compound filament (which usually is greater than one denier but less than two denier), is subjected to a splitting operation to separate the two polymers thereby creating a series of individual pie shaped sections disposed about a “star” shaped center. The pie sections are less than one denier and often as small as 0.01 to 0.2 denier or from 0.1 microns to 1 or 2 microns. It is this small fiber size and the small interstices between the fibers that give microfiber its superior wiping and drying characteristics. They also allow a web of material to be made that is thin enough to be rolled into a roll of less than eight inches diameter and still have sufficient strength and a length of at least thirty five yards (Typically with cloth toweling some fifty yards of material can be wound into a roll of suitable size to be housed in a conventional dispenser). These dimensions have been found necessary to use microfiber economically in a roll toweling conventional dispenser. Preferably the “split microfiber” consists of some twenty to thirty percent polyamide and seventy to eighty percent polyester.

For roll towel dispensers while the above fiber dimensions are important the “bulk” of the weave of the material is also a problem. It has been found that weaves such as used for clothing, thin dish towels, glass cleaner cloths (the so called flat weaves) function well for roll towel dispensers. High loft weaves such as “terry” weaves will become tangled in the rolls and jam the roll towel dispenser as well as increase roll size.

Various other configurations of synthetic fiber yarns are being developed almost daily and as long as they provide the small interstices and can meet the strength and bulk or flat weave requirements for roll toweling dispensers may be used with or in place of the foregoing fibers according to this invention.

According to the present invention we have found continuous roll toweling made from split microfiber, as defined herein, may be laundered and reused from two hundred to five hundred times before it must be discarded. Microfiber and especially split microfiber are initially more expensive than paper or cloth but its ability to withstand repeated cleaning and its superior absorbency ultimately results in a more economical product. In addition the ability of the microfiber to trap and hold soil material is far superior to currently available cloth or paper material.

OBJECTS AND SUMMARY OF INVENTION

It is therefore an object of the present invention to provide a roll towel material that is more economical to use than paper or cloth towels.

It is another object of the present invention to provide a roll towel material that is more efficient in trapping and holding soil than cloth or paper toweling.

It is yet another object of the present invention to provide a microfiber material that may be dispensed in a conventional roll towel dispenser.

It is a further object of the present invention to provide a microfiber roll towel material and apparatus for dispensing same, that is more efficient and economical to use than conventional paper or cloth roll towel dispensing devices.

It is yet another object of the present invention to provide roll towel dispensing apparatus capable of dispensing cloth, paper, microfiber, and split microfiber toweling interchangeably.

It is a still further object of the present invention to provide a roll towel dispensing apparatus that feeds a loop of clean toweling upon sensing the presence of an object to be wiped/dried and upon completion of the wiping/drying operation retracts the used towel and stretches a length of dean towel from the input to the output slots of the apparatus to prevent contact with soiled toweling and unwanted access to the external portion of the toweling material.

These and other and further objects of the invention are achieved in an embodiment of the invention in which a split microfiber roll toweling material is fed from a roll towel dispenser by a first powered means when the presence of an object to be wiped/dried is sensed and the used toweling material is retracted by a second powered means when the completion of the wiping/drying operation is sensed by the dispenser apparatus.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevational view of the roll towel dispenser according to the present invention;

FIG. 2 is a diagrammatic end view partially in section of the dispenser of FIG. 1 in the towel retracted at rest position;

FIG. 3 is a partial end view similar to FIG. 2 showing the roll towel dispenser with the toweling in the dispensed wiping/drying position

FIG. 4 is a block diagram of the control circuitry for operating the roll towel dispenser of the present invention; and

FIG. 5 is a block diagram of the sequential steps taken by the automatic towel dispenser apparatus.

DESCRIPTION OF PREFERRED EMBODIMENT

Referring now to FIG. 1 the roll towel dispenser 10 has a front cover 12 hinged at the upper edge so as to permit easy access to the frame (not shown) which is usually fixed to the wall or other support. A clean toweling bin 14 with false floor 16 (see FIG. 2) is pivotally fixed adjacent the bottom of the cover 12 and holds a roll 19 of dean toweling material 20. As discussed above in the conventional roll towel dispenser the roll diameter must be less than about eight inches to fit into bin 14 within the overall housing. With a flat weave split microfiber made from very small diameter fibers, rolls of this size will contain up to about fifty yards of material. This allows some 150 to 200 wiping/drying operations per roll which is equal to or better usage than with cloth rolls. Positioned below a false floor 16 in bin 14 is is the towel dispensing mechanism as will be described in more detail herein. Power supply and control circuitry may also be located here or further up in free space in cover 12.

Referring now to FIG. 2 a dean roll 19 of toweling 20 is positioned in bin 14. Toweling 20 is fed between a pair of rollers 22 and 24 to slot 28. Roller 24 is connected to a motor 26 which is powered from the power supply in the bottom of bin 14. Toweling 20 exits the cabinet through slot 28 at the front edge of the cabinet and is then directed back across the outer surface of bin 14 and up through the slot 30 at the rear of the dispenser. The toweling feed and retrieval slots shown are typical of currently available dispensers but the toweling may exit part way up the front of the cabinet 12 and return adjacent the bottom edge or otherwise of the housing as may be seen in other dispensers.

A tunnel member 31 extends from side to side of bin 14 below the bottom thereof and has a depth of about one half the front to back dimension of the dispenser housing 12. This ensures that only a small amount of used or dean toweling will remain exposed when the dispenser is in the rest position. In one option this small amount of dean towel is automatically fed out at the start off the used towel retrieval cycle. Alternatively the used towel is merely pulled into the tunnel and housing until stretched taught across the bottom.

The toweling is then fed up to roll 32. Roll 32 acts as the take up roll for the used toweling and is preferably constructed as shown in U.S. Pat. No. 6,745,974 incorporated herein by reference. Roll 32 is connected to a motor 36 by gear train 34. Motor 36 is powered by the power supply in bin 14. At rest toweling 20 is stretched tight across the bottom of the bin 14 through tunnel 31. While at rest rolls 28 and 32 are locked in place to prevent undesired access to the toweling and/or the bottom of the cabinet.

The rolls 22 and 24 usually have a frictionally enhanced surface in order to smoothly and positively grip and feed the cloth, paper or microfiber towel material. In the past “sandpaper” type surfaces have been used but we prefer a softer Neoprene or rubber like material. This is particularly important to prevent fibers of the microfiber material from catching and jamming the feeder mechanism. In other applications strips or bands of friction material are placed about the rolls. Suitable static remediation elements (not shown) are typically used to minimize user shock and control circuit interference.

Positioned adjacent the bottom front edge of the bin 14 are infra red windows 38 behind which are located emitter and receiver sensors 41 and 42 directed so as to sense the presence of an object to be wiped/dried such as a users hands.

Referring now to FIG. 4 a system block diagram of the circuitry for performing the operations of the dispenser is shown. With the unit in its powered up status the user places a hand or object slightly below the bottom front edge of the device whereby the infrared emitter 41 reflects from the users hand or object and enters the infrared receiver 42 The signal is then sent thorough amplifier 43 and to the respective circuitry within the micro controller 44 which then actuates dispensing motor 26 to dispense a preprogrammed length of dean or treated toweling 20 via the dispensing roller 24 which is linked to the dispensing motor 26. The toweling exits through the slot 28 forming a usable loop 46 of toweling 20 suitable for wiping or drying purposes as illustrated in FIG. 3.

With completed towel use, the hand 39 or object is drawn away from the toweling and the infrared sensor receiver 42 not longer receives a signal from the emitter 41. An adjustable dwell time is then effected by the micro controller 44. At the end of the dwell time a command is sent by the micro controller 44 to the dispensing motor 26 to dispense a short length of toweling 20 sufficient to extend from slot 28 to tunnel 31. When the short length dispensing is completed, a signal is sent from the micro controller 44 to the take up motor 36 and the used toweling is wound around the take up roller 32 linked thereto.

Roll motor 36 is energized long enough to take up the loop 46 of soiled toweling and also the small length of dean toweling just fed out by motor 26 until a stall condition is noted by a rise in motor current at which time the motor 36 is shut off. If a small length of dean toweling was fed out by motor 26 before soiled toweling take up is initiated it will cause the dean toweling to be drawn taught across the bottom of the bin 14 into tunnel 31. As indicated above this feeding of a small segment of dean toweling may be locked out and the micro controller will then go directly to the retrieval mode. Finally a locking pin or other means is energized to prevent further withdrawal of toweling by manual pulling or otherwise.

In the event the end of the toweling 20 is reached during the activation of motor 36 the toweling will be completely retracted and wound up about take up roll 32 eliminating the possibility of any used toweling dangling out of the bottom of dispenser 10. A time delay function is incorporated in micro controller 44 to turn off motor 36 if the stall condition noted above is not detected.

The control circuitry and motors 26 and 36 are powered by a power supply(not shown) which may take the form of throw away or rechargeable batteries or if desired a suitable rectified commercial power connection which could be hard wired in upon installation of the dispenser.

While there are given above certain specific examples of this invention and its application in practical use, it should be understood tat they are not intended to be exhaustive or to be limiting of the invention. On the contrary, these illustrations and explanations herein are given in order to acquaint others skilled in the art with this invention and the principles thereof and a suitable manner of its application in practical use. 

1. A continuous roll towel dispensing apparatus having a loop of roll towel material extending downwardly from a front dispensing slot to a return slot and in which a subsequent user obtains unused roll towel material by pulling downwardly on said material to dispense fresh unused towel material comprising: a back housing portion adaptable for mounting of said dispenser apparatus on a mounting surface; a front housing portion adapted to be connected to said back housing portion to form a compartment for containing at least a roll of dean unused towel material and a take up roll for used towel material; said front housing portion further defining with said back housing portion a dean towel dispensing slot and a used towel return slot; a used towel material take up roll operatively mounted within said housing portions; a roll of clean continuous microfiber towel material disposed in said housing; said dean microfiber towel material extending out of said clean towel dispensing slot forming a depending loop of towel material and then into said used towel return slot; and operating means operatively mounted within said housings to cause said roll of clean towel material to dispense a loop of dean toweling and said used towel take up roll to retrieve the used towel material when actuated by pulling down on said depending loop of towel material.
 2. The invention as claimed in claim 1 wherein said operating means includes: first roll and gear means engaging said dean microfiber towel material; second roll and gear means engaging said take up roll; and drive means engaging said first and second roll and gear means; whereby actuation of said first roll and gear means will actuate said second roll and gear means.
 3. The invention as claimed in claim 2 wherein the surface of at least one of said first and second roll means is at least partially covered with frictionally enhanced non abrasive material to ensure smooth feeding of microfiber material.
 4. The invention as claimed in claim 1 wherein said microfiber towel material comprises a split microfiber.
 5. The invention as claimed in claim 4 wherein said microfiber towel material comprises a flat weave microfiber.
 6. The invention as claimed in claim 5 wherein said split microfiber filaments are less than two denier.
 7. The invention as claimed in claim 4 wherein the fibers in said split microfiber are less than 50% polyamide fibers with the balance being polyester fibers.
 8. The invention as claimed in claim 2 wherein said dean roll of microfiber is less than eight inches in diameter and contains at least thirty five yards of material.
 9. The invention as claimed in claim 2 wherein said dean roll of microfiber material is less than eight inches in diameter and contains at least twenty yards.
 10. A roll of continuous toweling for use in a towel dispensing apparatus wherein a length of dean towel is presented for use and then retracted there into after use comprising: a length of microfiber material having a preselected width and a length greater than twenty yards; said material being formed from a flat weave split microfiber made from synthetic filament yarns of less than two denier; and said material having a thickness such that when rolled up into a roll of continuous material the resulting roll diameter is less than eight inches.
 11. The invention as claimed in claim 10 wherein said length of microfiber material has a length greater than thirty five yards.
 12. A continuous roll towel dispensing mechanism for selectively providing loop of towel material from a first slot in a housing to a second slot therein for performing a wiping//drying operation which comprises: a back housing portion adaptable for mounting of said dispenser on a mounting surface; a front housing portion adapted to be connected to said back housing portion to form a compartment containing; a roll of dean toweling material; a first means for feeding clean toweling material from said roll of clean toweling material to outside said housing; first motor power means for operating said first means for feeding; used roll towel material take up means mounted within said compartment; second motor power means for actuating said used towel material take up means; sensing means for determining when clean toweling is to be dispensed; sensing means for determining when used toweling needs to be retracted; control circuit means for operating said sensing means and said motor power means; power supply means for operating said control means, said sensing means, and said power means.
 13. The invention as claimed in claim 12 wherein; said first means for feeding has at least one roll positioned to feed clean roll towel material from said roll of dean toweling material to the outside of said compartment; said first motor power means includes a first stepping motor operatively connected to said at least one roll; said used towel take up means includes a take up roll mounted within said compartment; said second motor power means includes a second stepping motor operatively connected to said used towel take up roll; and said sensing means comprise an infrared emitter and infrared receiver mounted adjacent the bottom front of said compartment.
 14. The invention as claimed in claim 13 wherein said first means for feeding at least one roll has a frictionally enhanced surface suitable for feeding paper, cloth and microfiber towel material interchangeably.
 15. The invention as claimed in claim 14 wherein said frictionally enhanced surface is a non abrasive resilient material applied to at least a portion of said at least one roll surface.
 16. The invention as claimed in claim 12 wherein said control circuit means for said motor power means causes: first, said first motor power means to feed a first length of dean towel for wiping/drying and then before start of the retraction cycle a second smaller length of dean towel material; and second, said second motor power means to retract a length of toweling equal to said first length of clean towel fed by said first motor power means.
 17. The invention as claimed in claim 12 wherein said controll circuit means includes: means for causing said first motor power means to feed a length of dean toweling to form a loop of clean towel for wiping/drying; means for causing said second motor power means to retract said loop of dean towel upon completion of a wiping/drying operation; and means for turning off said second motor power means after a predetermined interval of time; whereby a dangling tail of towel material will be completely retracted within the dispensing mechanism before shutting down to rest condition.
 18. The invention as claimed in claim 12 wherein said dean toweling material comprises: a length of flat weave split microfiber material having a preselected width and a length greater than twenty five yards; said material being formed from a flat weave split microfiber made from synthetic filament yarns of less than two denier; and said material having a thickness such that when rolled up into a roll of continuous toweling material the resulting roll diameter is less than eight inches.
 19. The invention as claimed in claim 12 wherein said roll of clean toweling material may be made from paper, cloth, microfiber, split microfiber or flat weave microfiber interchangeably without causing said dispensing mechanism to malfunction.
 20. The invention as claimed in claim 12 wherein said roll of dean toweling material is positioned in the upper one half of said compartment and said used towel material take up roll is positioned in the lower one half of said compartment. 